2003 CHRYSLER VOYAGER service

PLUMBING - FRONT
WARNING
WARNING
WARNING:: THE ENGINE COOLING SYSTEM IS
DESIGNED TO DEVELOP INTERNAL PRESSURES
OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS
PER SQUARE INCH). DO NOT REMOVE OR
LOOSEN THE COOLANT PRESSURE CAP, CYLIN-
DER BLOCK DRAIN PLUGS, RADIATOR DRAIN,
RADIATOR HOSES, HEATER HOSES, OR HOSE
CLAMPS WHILE THE SYSTEM IS HOT AND UNDER
PRESSURE. FAILURE TO OBSERVE THIS WARNING
CAN RESULT IN SERIOUS BURNS FROM THE
HEATED ENGINE COOLANT. ALLOW THE VEHICLE
TO COOL FOR A MINIMUM OF 15 MINUTES
BEFORE OPENING THE COOLING SYSTEM FOR
SERVICE.
WARNING: THE ENGINE COOLING SYSTEM CON-
TAINS ANTIFREEZE. ANTIFREEZE IS AN ETHYLENE
GLYCOL BASED COOLANT AND IS HARMFUL IF
SWALLOWED OR IF THE VAPORS ARE INHALED. IF
SWALLOWED, DRINK TWO GLASSES OF WATER
AND INDUCE VOMITING. IF VAPORS ARE INHALED,
MOVE TO AN AREA FOR FRESH AIR. SEEK MEDI-
CAL ATTENTION IMMEDIATELY. DO NOT STORE IN
OPEN OR UNMARKED CONTAINERS. WASH SKIN
AND CLOTHING THOROUGHLY AFTER COMING IN
CONTACT WITH ETHYLENE GLYCOL. KEEP OUT
OF REACH OF CHILDREN.
WARNING: DISPOSE OF ETHYLENE GLYCOL
BASED COOLANT PROPERLY. CONTACT YOUR
DEALER OR A LOCAL GOVERNMENT AGENCY FOR
THE LOCATION OF AN APPROVED ETHYLENE GLY-
COL COLLECTION AND/OR RECYCLING CENTER IN
YOUR AREA.
WARNING - A/C PLUMBING
WARNING:: THE AIR CONDITIONING SYSTEM CON-
TAINS REFRIGERANT UNDER HIGH PRESSURE.
SEVERE PERSONAL INJURY MAY RESULT FROM
IMPROPER SERVICE PROCEDURES. REPAIRS
SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL.
WARNING: AVOID BREATHING THE REFRIGERANT
AND REFRIGERANT OIL VAPOR OR MIST. EXPO-
SURE MAY IRRITATE THE EYES, NOSE, AND/ORTHROAT. WEAR EYE PROTECTION WHEN SERVIC-
ING THE AIR CONDITIONING REFRIGERANT SYS-
TEM. SERIOUS EYE INJURY CAN RESULT FROM
DIRECT CONTACT WITH THE REFRIGERANT. IF
EYE CONTACT OCCURS, SEEK MEDICAL ATTEN-
TION IMMEDIATELY.
WARNING: DO NOT EXPOSE THE REFRIGERANT
TO OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC LEAK DETECTOR IS RECOMMENDED.
WARNING: IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
WARNING: THE EVAPORATION RATE OF R-134a
REFRIGERANT AT AVERAGE TEMPERATURE AND
ALTITUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.
WARNING: THE R-134a SERVICE EQUIPMENT OR
THE VEHICLE REFRIGERANT SYSTEM SHOULD
NOT BE PRESSURE TESTED OR LEAK TESTED
WITH COMPRESSED AIR. SOME MIXTURES OF AIR
AND R-134a HAVE BEEN SHOWN TO BE COMBUS-
TIBLE AT ELEVATED PRESSURES. THESE MIX-
TURES ARE POTENTIALLY DANGEROUS, AND MAY
RESULT IN FIRE OR EXPLOSION CAUSING INJURY
OR PROPERTY DAMAGE.
CAUTION - A/C PLUMBING
CAUTION:: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions supplied
with the service equipment being used.
CAUTION: Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
CAUTION: R-12 refrigerant oil must not be mixed
with R-134a refrigerant oil. They are not compatible.
RSPLUMBING - FRONT24-61
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CAUTION: Do not use R-12 equipment or parts on
the R-134a system. Damage to the system will
result. All parts, tools, and equipment must be
designed for R-134a refrigerant.
CAUTION: Do not discharge refrigerant into the
atmosphere. Use an R-134a refrigerant recovery/re-
cycling device that meets SAE Standard J2210.
CAUTION: The refrigerant must be recovered com-
pletely from the system before opening any fitting
or connection. Open the fittings with caution, even
after the system has been discharged. If any pres-
sure is noticed as a fitting is loosened, tighten the
fitting and recover the refrigerant from the system
again.
CAUTION: The refrigerant system must always be
evacuated before charging.
CAUTION: Do not overcharge the refrigerant sys-
tem. This will cause excessive compressor head
pressure and can cause noise and system failure.
CAUTION: Do not open the refrigerant system or
remove the sealing caps from a replacement com-
ponent until it is to be installed. This will prevent
contamination in the system.
CAUTION: Before disconnecting a component,
clean the outside of the fittings thoroughly to pre-
vent contamination from entering the refrigerant
system.
CAUTION: When it is necessary to open the refrig-
erant system, have everything needed to service
the system ready. Immediately after disconnecting a
component from the refrigerant system, seal the
open fittings with a cap or plug to prevent the
entrance of dirt and moisture. The refrigerant sys-
tem should not be left open to the atmosphere any
longer than necessary.
CAUTION: Before connecting an open refrigerant
fitting, always install a new seal and or gasket. All
fittings with O-rings need to be coated with refrig-
erant oil before installation. Use only O-rings that
are the correct size and approved for use with
R-134a refrigerant. Failure to do so may result in a
leak. Coat the fitting and seal with clean refrigerant
oil before connecting. Unified plumbing connec-tions with gaskets cannot be serviced with O-rings.
The gaskets are not reusable and new gaskets do
not require lubrication before installing.
CAUTION: When installing a refrigerant line, avoid
sharp bends that may restrict refrigerant flow. A
good rule for the flexible hose refrigerant lines is to
keep the radius of all bends at least ten times the
diameter of the hose. Sharp bends will reduce the
flow of refrigerant.
CAUTION: Position the refrigerant lines away from
exhaust system components or any sharp edges,
which may damage the line. The flexible hose lines
should be routed so they are at least 80 millimeters
(3 inches) from the exhaust manifold. Inspect all
flexible refrigerant system hose lines at least once
a year to make sure they are in good condition and
properly routed.
CAUTION: High pressures are produced in the
refrigerant system when it is operating. Extreme
care must be exercised to make sure that all refrig-
erant system connections are pressure tight.
CAUTION: Tighten refrigerant fittings only to the
specified torque. The aluminum fittings used in the
refrigerant system will not tolerate overtightening.
CAUTION: When disconnecting a refrigerant fitting,
use a wrench on both halves of the fitting. This will
prevent twisting of the refrigerant lines or tubes.
CAUTION: Refrigerant oil will absorb moisture from
the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to
use it. Replace the cap on the oil container immedi-
ately after using. Store refrigerant oil only in a
clean, airtight, and moisture-free container.
CAUTION: All tools, including the refrigerant recy-
cling equipment, the manifold gauge set, and test
hoses should be kept clean and dry. Keep the work
area clean. Contamination of the refrigerant system
through careless work habits must be avoided. The
refrigerant system will remain chemically stable as
long as pure, moisture-free R-134a refrigerant and
refrigerant oil is used. Dirt, moisture, or air can
upset this chemical stability. Operational troubles
or serious damage can occur if foreign material is
introduced to the refrigerant system.
24 - 62 PLUMBING - FRONTRS
PLUMBING - FRONT (Continued)
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A/C COMPRESSOR
DESCRIPTION
All vehicles use the Nippondenso 10S20 compres-
sor. This compressor use an aluminum swash plate,
teflon coated pistons and aluminum sleeveless cylin-
der walls. This compressor includes an integral high
pressure relief valve. The compressor is secured low
in the right front corner of the engine compartment
to a mounting bracket on the cylinder block (2.4L
engine), or directly to the cylinder block (3.3L and
3.8L engines) is integral to the compressor. This com-
pressor cannot be repaired. If faulty or damaged, the
entire compressor must be replaced. The compressor
clutch, pulley, and clutch coil are available for service
replacement.
OPERATION
The compressor is driven by the engine through an
electric clutch, drive pulley and belt arrangement.
The compressor is lubricated by refrigerant oil that is
circulated throughout the refrigerant system with the
refrigerant. The compressor draws in low-pressure
refrigerant vapor from the evaporator through its
suction port. It then compresses the refrigerant into
a high-pressure, high-temperature refrigerant vapor.
The compressor pumps high-pressure refrigerant
vapor to the condenser through the compressor dis-
charge port. The mechanical high pressure relief
valve is designed to vent refrigerant from the system
to protect against damage to the compressor or other
system components, caused by condenser air flow
restrictions or an overcharge of refrigerant. The valve
only vents enough refrigerant to reduce the system
pressure, then re-seats itself. The valve opens at a
discharge pressure of 3445 to 4135 kPA (500 to 600
psi) or above, and closes when a minimum discharge
pressure of 2756 kPa (400 psi) is reached.
DIAGNOSIS AND TESTING - COMPRESSOR
NOISE DIAGNOSIS
Excessive noise while the air conditioning compres-
sor is operating can be caused by loose compressor
mounts, a loose compressor clutch, or high operating
pressures in the refrigerant system. Verify compres-
sor drive belt condition, proper compressor mounting,
correct refrigerant charge level, and compressor head
pressure before compressor repair is performed.
With the close tolerances within the compressor, it
is possible to experience a temporary lockup. The
longer the compressor is inactive, the more likely the
condition is to occur. This condition is the result of
normal refrigerant migration within the refrigerant
system caused by ambient temperature changes. Therefrigerant migration may wash the refrigerant oil
out of the compressor.
NOTE: Prior to a vehicle being removed from ser-
vice or stored for more than two weeks, the com-
pressor should be operated to ensure adequate
refrigerant oil distribution throughout the system
components. Turn on the air conditioner for a min-
imum of five minutes with outside air and the high-
est blower speed selected.
BELT NOISE
If the compressor drive belt slips at initial start-up,
it does not necessarily mean the compressor has
failed. The following procedure can be used to iden-
tify a compressor drive belt noise problem.
A. Start the vehicle and run at idle.
B. Turn the air conditioner On and listen for belt
squeal.
C. If belt squeal is heard, turn the air conditioner
Off immediately.
If the belt squeal stops when the air conditioner is
turned Off, perform the following repair procedures.
(1) Using an appropriate sized oil filter wrench or
a strap wrench, grasp the outer diameter of the com-
pressor clutch hub. While facing the compressor,
rotate the hub clockwise, then counterclockwise. If
the hub rotates, proceed to the next step. If the hub
will not rotate, the compressor is internally damaged,
and must be replaced.
(2) Turn the hub clockwise five complete revolu-
tions and remove the tool.
(3) Start the vehicle and run at idle.
(4) Turn the air conditioner On. Observe the com-
pressor and the system for normal operation, noting
cooling performance and noise levels. Operate for five
minutes before turning the air conditioner Off. If
acceptable cooling performance is observed during
compressor operation, the compressor does not need
to be replaced.
(5) Inspect the drive belt for wear, damage, and
proper tension. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND TEST-
ING).
RSPLUMBING - FRONT24-63
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(16) Reconnect the battery negative cable.
(17) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(18) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
INSTALLATION - COMPRESSOR MOUNTING
BRACKET - 2.4L ENGINE
(1) Position the compressor mounting bracket onto
the engine.
(2) Install and tighten the four screws that secure
the compressor mounting bracket to the engine.
Tighten the screws to 54 N´m (40 ft. lbs.).
(3) Reinstall the compressor onto the mounting
bracket. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/COMPRESSOR - INSTALLA-
TION).
CONDENSER
DESCRIPTION
The condenser is integral to a cooling module
which includes the radiator, the electric cooling fan,
the fan shroud, air seals and an automatic transmis-
sion oil cooler. The cooling module is located in the
air flow in the front of the engine compartment
behind the radiator grille. The condenser cannot be
repaired or adjusted and, if faulty or damaged, it
must be replaced. The condenser may be removed
from the cooling module for service without removing
the cooling module from the vehicle.
OPERATION
The condenser is a heat exchanger that allows the
high-pressure refrigerant gas being discharged by the
compressor to give up its heat to the air passing over
the condenser fins. When the refrigerant gas gives up
its heat, it condenses. When the refrigerant leaves
the condenser, it has become a high-pressure liquid
refrigerant. The volume of air flowing over the con-
denser fins is critical to the proper cooling perfor-
mance of the air conditioning system. Therefore, it is
important that there are no objects placed in front of
the radiator grille openings in the front of the vehicle
or foreign material on the condenser fins that might
obstruct air flow. Also, any factory-installed air seals
or shrouds must be properly reinstalled following
radiator or condenser service.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These air seals are used to direct air through
the condenser and radiator. The air seals must be
reinstalled in their proper locations in order for the
air conditioning and engine cooling systems to per-
form as designed.
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Remove the two large screws that secure the
front fascia and the outboard ends of the radiator
sight shield to the radiator closure panel crossmem-
ber (Fig. 4).
(3) Remove the five small screws that secure the
front fascia grille inserts to the radiator sight shield.
(4) Remove the radiator sight shield from the radi-
ator closure panel crossmember.
(5) Remove the two screws that secure the hood
latch unit to the front of the radiator closure panel
Fig. 4 Radiator Sight Shield
1 - LARGE SCREWS (2)
2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
5 - FRONT FASCIA
24 - 66 PLUMBING - FRONTRS
A/C COMPRESSOR (Continued)
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through the evaporator tubes. The heater-A/C unit
housing must be removed from the vehicle to access
the evaporator for service. The evaporator cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.
OPERATION
Refrigerant enters the evaporator from the expan-
sion valve as a low-temperature, low-pressure liquid/
vapor mixture. As air flows over the fins of the evap-
orator, the humidity in the air condenses on the fins,
and the heat from the air is absorbed by the refrig-
erant. Heat absorption causes the refrigerant to boil
and vaporize. The refrigerant becomes a low-pressure
gas when it leaves the evaporator.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING),
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING),
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - HEATER PLUMB-
ING).
(1) Remove the HVAC unit housing from the vehi-
cle. (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION - FRONT/HVAC HOUSING -
REMOVAL).
(2) Remove the heater core tubes from the heater
core. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER CORE -
REMOVAL - HEATER CORE TUBES).
(3) Remove and discard the foam seal from the
HVAC housing seal flange around the fresh air inlet
opening and the expansion valve/evaporator tube
opening on the dash panel side of the unit.
(4) Remove the expansion valve from the evapora-
tor inlet and outlet tube fittings. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/EXPANSION VALVE - REMOVAL).
(5) Disconnect the HVAC wire harness connector
for the blower motor from the motor connector recep-
tacle on the bottom of the outboard end of the evap-
orator housing.
(6) Disengage the HVAC wire harness from the
routing clips molded into the outside of the HVAC
housing components.
(7) Remove the four screws from the dash panel
side of the unit that secure the top of the distribution
housing to the inboard end of the evaporator housing
(Fig. 9).(8) Pull the top of the distribution housing away
from the evaporator housing far enough to disengage
the two hook formations on the bottom of the distri-
bution housing from the two receptacles on the evap-
orator housing (Fig. 10).
(9) Remove the two screws that secure the upper
intake air housing to the lower intake air housing.
(10) Remove the three screws that secure the
upper intake air housing to the top of the outboard
end of the evaporator housing. Be certain not to miss
the screw located just inside the inboard side of the
fresh air intake opening.
(11) Remove the upper intake air housing from the
top of the evaporator housing to expose the recircu-
Fig. 9 HVAC Housing
1 - DISTRIBUTION HOUSING
2 - SCREWS (3)
3 - HVAC WIRING HARNESS
4 - ROUTING CLIP
5 - EVAPORATOR HOUSING
Fig. 10 Distribution Housing Hooks
1 - RECEPTACLES ON EVAPORATOR HOUSING
2 - HOOKS ON DISTRIBUTION HOUSING
24 - 70 PLUMBING - FRONTRS
EVAPORATOR (Continued)
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NOTE: Liquid CO2is required to test the expansion
valve. This material is available from most welding
supply facilities. Liquid CO
2is also available from
companies which service and sell fire extinguish-
ers.
When testing the expansion valve, the work area
and the vehicle temperature must be 21É to 27É C
(70É to 85É F). To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. Verify the
refrigerant charge level.
(2) Close all doors, windows and vents to the pas-
senger compartment.
(3) Set the heater-air conditioner controls so that
the compressor is operating, the temperature control
is in the highest temperature position, the mode door
is directing the output to the floor outlets, and the
blower is operating at the highest speed setting.
(4) Start the engine and allow it to idle at 1000
rpm. After the engine has reached normal operating
temperature, allow the passenger compartment to
heat up. This will create the need for maximum
refrigerant flow into the evaporator.
(5) If the refrigerant charge is sufficient, the dis-
charge (high pressure) gauge should read 965 to 1655
kPa (140 to 240 psi). The suction (low pressure)
gauge should read 140 kPa to 207 kPa (20 psi to 30
psi). If OK, go to Step 6. If not OK, replace the faulty
expansion valve.
WARNING:
PROTECT THE SKIN AND EYES FROM EXPOSURE
TO LIQUID CO
2. PERSONAL INJURY CAN RESULT.
(6) If the suction (low pressure) gauge reads
within the specified range, freeze the expansion valve
control head for 30 seconds using liquid CO
2or
another suitable super-cold material.Do not spray
R-134a or R-12 refrigerant on the expansion
valve control head for this test.The suction (low
pressure) gauge reading should drop by 10 psi. If OK,
go to Step 7 If not OK, replace the faulty expansion
valve.
(7) Allow the expansion valve control head to thaw.
The suction (low pressure) gauge reading should sta-
bilize at 140 kPa to 240 kPa (20 psi to 30 psi). If not
OK, replace the faulty expansion valve.
(8) When expansion valve testing is complete, test
the overall air conditioner performance. (Refer to 24 -
HEATING & AIR CONDITIONING - DIAGNOSIS
AND TESTING - A/C PERFORMANCE TEST).
Remove all test equipment before returning the vehi-
cle to service.
REMOVAL
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/REFRIGERANT -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY).
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the air cleaner housing from the right
side of the engine compartment.
(4) Disconnect the drain tube from the wiper mod-
ule drain on the right side of the engine compart-
ment.
(5) Disconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer from
the transducer on the front liquid line rear section
(Fig. 14).
(6) Remove the screw that secures the front liquid
line rear section fitting to the top of the filter-drier.
(7) Disconnect the liquid line fitting from the fil-
ter-drier outlet port.
(8) Remove the seal from the liquid line fitting and
discard.
Fig. 14 Expansion Valve
1 - A/C PRESSURE TRANSDUCER
2 - EVAPORATOR TEMPERATURE SENSOR
3 - EXPANSION VALVE
4 - SUCTION LINE
5 - HIGH SIDE SERVICE PORT
6 - FRONT LIQUID LINE REAR SECTION
RSPLUMBING - FRONT24-73
EXPANSION VALVE (Continued)
ProCarManuals.com

(9) Install plugs in, or tape over the opened liquid
line fitting and the filter-drier outlet port.
(10) Remove the nut that secures the suction line
and liquid line fittings to the stud on the expansion
valve.
(11) Disconnect the suction line and liquid line fit-
tings from the expansion valve and move the lines
out of the way.
(12) Remove the seals from the suction line and
liquid line fittings and discard.
(13) Install plugs in, or tape over the opened suc-
tion line and liquid line fittings and both expansion
valve ports.
(14) Remove the two screws that secure the expan-
sion valve to the evaporator tube tapping plate.
(15) Disconnect the HVAC wire harness connector
for the evaporator temperature sensor from the sen-
sor on the top of the expansion valve.
(16) Remove the expansion valve from the evapo-
rator inlet and outlet tube fittings.
(17) Remove the seals from the evaporator inlet
and outlet tube fittings and discard.
(18) Install plugs in, or tape over the opened evap-
orator inlet and outlet tube fittings and both expan-
sion valve ports.
INSTALLATION
(1) Remove the tape or plugs from the evaporator
inlet and outlet tube fittings and both ports on the
back of the expansion valve.
(2) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the evaporator
inlet and outlet tube fittings.
(3) Position the expansion valve onto the evapora-
tor inlet and outlet tube fittings.
(4) Install and tighten the two screws that secure
the expansion valve to the evaporator tube tapping
plate plate. Tighten the screws to 11 N´m (97 in.
lbs.).
(5) Reconnect the HVAC wire harness connector
for the evaporator temperature sensor to the sensor
connector receptacle on the top of the expansion
valve.
(6) Remove the tape or plugs from the front liquid
line rear section and suction line fittings for the
expansion valve and both ports on the front of the
expansion valve.
(7) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the front liquid
line rear section and suction line fittings for the
expansion valve.
(8) Reconnect the liquid line and suction line fit-
tings to the expansion valve.
(9) Install and tighten the nut that secures the
suction line and liquid line fittings to the stud on theexpansion valve. Tighten the nut to 23 N´m (17 ft.
lbs.).
(10) Remove the tape or plugs from the liquid line
rear section fitting for the filter-drier and the filter-
drier outlet port.
(11) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(12) Reconnect the liquid line fitting to the filter-
drier outlet port on the top of the filter-drier.
(13) Install and tighten the screw that secures the
liquid line fitting to the filter-drier. Tighten the screw
to 11 N´m (100 in. lbs.).
(14) Reconnect the headlamp and dash wire har-
ness connector for the A/C pressure transducer to the
transducer on the front liquid line rear section.
(15) Reconnect the drain tube to the wiper module
drain on the right side of the engine compartment.
(16) Reinstall the air cleaner housing into the
right side of the engine compartment.
(17) Reconnect the battery negative cable.
(18) Evacuate the refrigerant system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(19) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
HEATER CORE
DESCRIPTION
The heater core is located in the distribution hous-
ing of the heater-A/C unit, under the instrument
panel. It is a heat exchanger made of rows of tubes
and fins. One end of the core is fitted with a molded
plastic tank that includes integral heater core inlet
and outlet ports. The removable heater core tubes
are held in place these ports by a sealing plate
secured with a screw to the heater core tank. This
removable heater core tube arrangement allows the
heater core to be serviced without removing the heat-
er-A/C unit housing from the vehicle. The heater core
cannot be repaired and, if faulty or damaged, it must
be replaced.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The blend air door
allows control of the heater output air temperature
by controlling how much of the air flowing through
24 - 74 PLUMBING - FRONTRS
EXPANSION VALVE (Continued)
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the heater-A/C unit housing is directed through the
heater core.
REMOVAL
REMOVAL- HEATER CORE EXTENSION TUBES
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Drain the engine cooling system. (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the heater hoses from the heater
hose tubes. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/HEATER HOSE -
REMOVAL).
(4) Remove the silencer from beneath the driver
side end of the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL SILENCER - REMOVAL).
(5) Remove the three screws that secure the heater
core shield to the left end of the HVAC distribution
housing (Fig. 15).
(6) Pull the heater core shield rearward far enough
to disengage the two location tabs that position the
front of the shield to the receptacles in the two lower
finger formations of the evaporator housing near the
dash panel.
(7) Remove the heater core shield from the distri-
bution housing.
(8) Take the proper precautions to protect the car-
peting below the heater core from spilled engine cool-ant and have absorbent toweling readily available to
clean up any spills.
(9) Remove the screw that secures the heater core
tube sealing plate to the heater core supply and
return ports (Fig. 16).
(10) Push both heater core tubes simultaneously
toward the dash panel far enough to disengage their
fittings from the heater core supply and return ports.
(11) Install plugs in, or tape over the opened
heater core tube fittings and both heater core ports.
Fig. 15 Heater Core Shield
1 - HEATER/ AIR CONDITIONER HOUSING
2 - HEATER CORE SHIELD
3 - DISTRIBUTION HOUSING
4 - SCREWS (3)
5 - LOCATION TABS (2)
Fig. 16 Heater Core Tubes
1 - SEAL
2 - HEATER CORE TUBES
3 - SCREW
4 - HEATER CORE
5 - DISTRIBUTION HOUSING
6 - SEALING PLATE
RSPLUMBING - FRONT24-75
HEATER CORE (Continued)
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